Process for making shearform matrix

ABSTRACT

The present invention is a unique process and apparatus for making a new matrix material called a shearform matrix which results in transformation of the morphology of a feedstock. The process is characterized by increasing the temperature of a nonsolubilized feedstock carrier to a point where it will undergo internal flow, followed by ejecting a stream of the feedstock and then subjecting it to disruptive fluid shear force which separates it into separate parts or masses which have a transformed morphology. The shearform matrix may include other ingredients such as oleaginous material and actives.

BACKGROUND OF THE INVENTION

The present invention relates to a unique process and apparatus formaking a new matrix material resulting from transformation of themorphology of feedstock material.

The art of material processing has developed significantly in recentyears. Increased awareness of the impact that different substances haveon the environment and on the species found therein has fostered avirtual explosion of technology for providing alternative forms ofmaterial. Well-known substances have been subjected to close scrutiny todiscover clean, efficient, and controlled methods of handling andexposing them to the world. It is also important to develop new forms ofmaterial for application in various fields.

One area of material processing includes technology which relates to thereduction of material structure by use of heat during processing.Processing food and food ingredients many times includes suchtechnology.

For example, a series of U.S. patents issued to Thomas E. Chivers (U.S.Pat. No. 3,762,846, U.S. Pat. No. 3,723,134, and U.S. Pat. No.3,557,717) disclose a solution process for making candy floss from acooked slurry or syrup. The ingredients are blended and heated at afirst temperature, e.g., 200°-205° F. (93°-96° C.), to form a slurry.After forming the slurry, the batch is cooked or boiled at asubstantially higher temperature, e.g., about 340° F. (171.1° C.), andthereafter discharged through an atomizing nozzle. Most of the moisturecontained in the molten candy flashes off as it is discharged. TheChivers disclosures rely on dissolution of the ingredients, e.g., sugarand other ingredients, in water and then heating extensively to drivethe water from the solution. Most of the water is driven off afterdischarging the solution. Thus, the Chivers technology suffers fromdrawbacks associated with sustained high temperature processing anddissolution of ingredients during processing.

Another method for process material is disclosed in European PatentApplication 0 387 950 A1 of Stork. The Stork process is a method ofpreparing a foam spray-dried product by collision of a stream of gaswhich contains dry particulate material, with a jet of droplets of aliquid solution. A liquid solution which contains at least one of theingredients of the end product is combined with gas and heated beforespraying as a jet of droplets for collision with the dry particulate.The Stork system is designed to process a low density product; itrequires an elaborate equipment arrangement, and is energy intensive.

UK Patent Specification G B 2 155 934 B of Shukla, et al. discloses amethod for crystallizing sucrose or glucose from a solution. Shukla, etal. subject a sugar solution to evaporation to produce a supersaturatedsugar solution. The supersaturated solution is then subjected to shearin a continuous screw extruder to induce nucleation. The retention timeof the syrup is below 25 seconds (on the average) at a temperature of115° C. to 145° C. (239° F.-293° F.) for sucrose and 100° C.-135° C.(215° F.-275° F.) for glucose. After the syrup is subjected toprogressive nucleation, Shukla, et al. pass the syrup onto a moving bandto permit crystallization to continue at a gradual rate at relativelyhigh temperature. The Shukla, et al. process requires maintenance of thesolution at temperatures which do not drop below the boiling point ofwater.

Other disclosures include British Patent Specification No. 1 460 614 andU.S. Pat. No. 3,972,725 (Tate & Lyle Limited) which disclose acontinuous process wherein a syrup solution is catastrophicallynucleated and discharged into a crystallization zone. Catastrophicnucleation is achieved by subjecting the solution to shear force whichcan be applied in an apparatus such as a colloid mill or homogenizer.The solution is discharged onto a moving band where the water must beboiled off by maintaining the material at a relatively high temperature.A related process has been disclosed in British Patent Specification 2070 015 B and U.S. Pat. No. 4,342,603, which is used for crystallizationof glucose. In the disclosed procedure, a supersaturated solution issubjected to shear force and allowed to crystallize on a belt. Both thesucrose process and the glucose process require solution processing athigh temperatures and are, consequently, energy intensive.

U.S. Pat. No. 3,365,331 to Miller, U.S. Pat. No. 4,338,350 and U.S. Pat.No. 4,362,757 describe a process for crystallizing sugar, which involvesimpact beating a sugar solution to provide nucleation. The processinvolves input of considerable amount of energy and has problemsdirectly related to temperature control.

U.S. Pat. No. 3,197,338 to Hurst, et al. discloses a process forcrystallizing glucose which includes kneading a glucose solution toinduce nucleation followed by crystallization to form a solid glasswhich is then ground. Another glucose crystallization process has beendisclosed in GB 2 077 270 B in which starch hydrolyzate is concentratedby evaporation and then simultaneously crushed and mixed duringcrystallization while cooling. The product is further milled. Theseprocesses also require nucleating by beating a solution which includesglucose.

More recently, technology for material processing has been disclosed byDr. Richard C. Fuisz. In U.S. Pat. No. 4,855,326 various substanceshaving pharmological properties were combined with sugar and spun toproduce a readily water-soluble product. Other disclosures which relateto spinning substances with one or more sugars are found in U.S. Pat.No. 4,873,085, U.S. Pat. No., 5,034,421, U.S. Pat. No. 4,997,856 andU.S. Pat. No. 5,028,632. U.S. Pat. No. 5,034,421 to Fuisz discloses spunmatrix systems containing medicaments having predetermined releasepatterns.

The examples in the Fuisz disclosures set forth above describeprocessing feedstock material by subjecting it to high speed spinning ona spinning head in which the substance is also subjected to heatingagainst a heating element. The change of temperature is quite large,which is believed to be occasioned by the spinning head quickly andefficiently spreading the feedstock material against the heating elementcircumferentially disposed around the perimeter of the spinning head.Thus, extensive surface contact of the feedstock is provided against theheating element itself while being spun.

The feedstock material is heated sufficiently to create an internal flowcondition which permits part of the feedstock to move at a subparticlelevel with respect to the rest of the mass and exit openings provided inthe perimeter of the spinning head. The centrifugal force created in thespinning head flings the flowing feedstock material outwardly from thehead so that it reforms with a changed structure. The force required toseparate and discharge flowable feedstock is only the centrifugal forcewhich results from the spinning head. These examples describe oneapproach to producing a novel matrix material.

It is an object of the present invention to overcome drawbacks which areassociated with the non-Fuisz procedures. It is also an object of thepresent invention to provide improvements over the technology previouslydisclosed and claimed by Dr. Fuisz.

SUMMARY OF THE INVENTION

The present invention is a unique process and apparatus for making ashearform matrix by raising the temperature of a feedstock materialwhich includes a non-solubilized carrier to a point where the carrierundergoes internal flow upon application of a fluid shear force. Thefeedstock is advanced and ejected while in internal flow condition, andsubjected to disruptive fluid shear force to form multiple parts ormasses which have a morphology different from that of the originalfeedstock.

The multiple masses are cooled substantially immediately after contactwith the fluid shear force and are permitted in accordance with thepresent invention to continue in a free-flow condition until solidified.Accordingly, conditions are provided at the point of shear whereby thefeedstock is maintained in a free-flow condition until the new massesare beyond the shearing step.

Ideally the temperature of gas is controlled when used as theshear-producing fluid. The temperature is controlled to provide a gastemperature which is at least 0.1° C. greater than the flow pointtemperature of material being ejected for each atmosphere of pressure ofgas applied against said material as a shear force. Thus, if there are10 atmospheres of pressure applied, the temperature of gas should be atleast 1° C. greater than the temperature of the material being ejected.This feature has been found to optimize the shearing effect and maintainthe ejected feedstock in free-flow condition until it is separated andhas traveled beyond the shear step.

The feedstock material used in the present process is one which includesa carrier selected from the group consisting of saccharide-basedmaterials, thermoplastic polymers, biodegradable polymers andcellulosics. Preferably the feedstock material is organic, that is mostcompounds of carbon. Basically, the feedstock is selected for use hereinbased on the ability to be processed without reliance upon dissolution.The feedstock material may contain minor amounts of material which isdissolved, but the processability of the feedstock relies on a carriercapable of undergoing internal flow without the necessity ofdissolution. In the case of saccharide-based materials, the feedstock isprimarily a solid material which is subjected to the process.

The term saccharide-based materials includes sugars and sugarderivatives. Sugars are referred to in a classical sense which meanssucrose, maltose, fructose, lactose, glucose, arabinose, xylose,galactose, et al. Sugar alcohols are also included in the term sugars. Anon-limiting list of sugar alcohols includes the following: sorbitol,mannitol, maltitol, pentatol, isomalt (Palatinit®), xylitol, et al.Sugar derivatives include chemical and enzymatic derivatives andincludes, but is not limited to, chloro derivatives of sugar such assucralose.

Saccharide-based materials can have varying degrees of low-monomersaccharides, or sugars, oligomers, and polysaccharides, such as starch.Some saccharide-based materials are prepared by hydrolysis of starch andare classified by the degree of starch polymer hydrolysis. The measuringunit is referred to as D.E. or dextrose equivalent. D.E. is defined asreducing sugars expressed as dextrose and reported as a percentage ofthe dry substance.

A saccharide-based material having high short-carbon-chain content,e.g., glucose and low-unit oligomers thereof, usually results in ahigher dextrose equivalent, (D.E.). However, saccharide-based materialhaving greater long-carbon-chain content, e.g. high monomer unitoligomers and polymers usually results in a lower D.E. rating.

For example, maltodextrins contain a mix of sugars and polysaccharideswhich range from long-chain oligomers resulting from starch hydrolysisto sugars having a low number of monomeric units. Under FDA guidelinesmaltodextrin consists of nonsweet, nutritive saccharide polymers havinga D.E. of less than 20, while corn syrup solids is regarded by the FDAas having a D.E. greater than 20. The present inventors, however, referto maltodextrins collectively as saccharide-based material consisting ofnonsweet, nutritive saccharide polymers and other oligomers havingsix-carbon monomer units which collectively provide a carrier materialcapable of forming a matrix. In all uses, the carrier material in thepresent invention is nonsolubilized.

In a preferred embodiment of the present invention, other materials canbe included in the feedstock. For example, oleaginous material can beincluded in the feedstock which, among other things, can act as acrystallization-control agent. By crystallization-control agent is meantthat the matrix which is formed as a result of the present process andapparatus can be in an amorphous condition and subjected to anenvironment in which it will crystallize in a controlled manner. Otherhydrophobics may be used as a control for crystallization and arecontemplated to be part of the present invention. Some of the oleaginousmaterials which are contemplated for use in the present invention are asfollows: vegetable oils, soy bean oil, canola oil, corn oil, cocoabutter, sunflower oil, animal fats, tallows, lards, fish oils,crustacean oils, and mixtures thereof.

The feedstock can also contain an additive selected from the groupconsisting of bioeffecting agents, dyes, fragrances, crystallizationcontrol agents, sweeteners, flavors, and mixtures thereof. Anon-limiting list of bioeffecting agents is as follows: antitussives,antihistamines, decongestants, alkaloids, mineral supplements,laxatives, vitamins, antacids, ion exchange resins,anti-cholesterolemics, anti-lipid agents, antiarrhythmics, antipyretics,analgesics, appetite suppressants, expectorants, anti-anxiety agents,anti-ulcer agents, anti-inflammatory substances, coronary dilators,cerebral dilators, peripheral vasodilators, anti-infectives,psycho-tropics, antimanics, stimulants, gastrointestinal agents,sedatives, antidiarrheal preparations, anti-anginal drugs,vasodialators, anti-hypertensive drugs, vasoconstrictors, migrainetreatments, antibiotics, tranquilizers, anti-psychotics, antitumordrugs, anticoagulants, antitnrombotic drugs, hypnotics, anti-emetics,anti-nauseants, anti-convulsants, neuromuscular drugs, hyper- andhypoglycemic agents, thyroid and antithyroid preparations, diuretics,antispasmodics, uterine relaxants, mineral and nutritional additives,antiobesity drugs, anabolic drugs, erythropoietic drugs, antiasthmatics,cough suppressants, mucolytics, anti-uricemic drugs and mixturesthereof.

Since a number of bio-affecting agents are heat sensitive, the presentinvention includes a process step of introducing heat sensitive agentsat a point sufficiently proximal the ejection step to reduce exposure ofthe heat sensitive to prolonged heat conditions. Thus, any heatsensitive agent can De incorporated into a carrier for subsequentejection and formation of a shearform matrix product.

In order to implement the unique process, an apparatus is provided whichhas a means for increasing the temperature of a non-solubilizedfeedstock and simultaneously increasing the applied pressure on thefeedstock to advance it for ejection. Preferably, this means forincreasing and advancing the feedstock can be a multiple heating zonetwin screw extruder. Preferably there are greater than four (4) zones,and in the present preferred mode there are nine (9) zones.

The second element: of the apparatus is a means for ejecting thefeedstock in a condition for shearing it to provide the shearformmatrix- The means for ejecting is in fluid communication with the meansfor increasing the temperature and pressure and is arranged at a pointto receive the feedstock while it is in the internal flow condition.Preferably this means for ejecting the feedstock is a nozzle whichprovides high pressure ejection of the feedstock material. In order tomaintain the free-flow condition of the matrix beyond the point ofshear, it is preferable to include temperature-maintenance meansthroughout the means for ejecting.

In a preferred embodiment, the apparatus can also include a port forintroducing an additive or agent to the carrier at a point close enoughto ejection to prevent or minimize degradation of the agent. In this wayheat sensitive agents can be introduced without fear of losing theiractivity--e.g., bio-affecting properties.

Finally, the apparatus includes a means for shearing the feedstock whichis arranged proximally to the ejector and is disposed to effect shear ofthe feedstock while it is in the internal flow condition. Preferable themeans for shearing is a means for delivering fluid such as air at highvelocity against the feedstock stream as it exits a nozzle. Such adevice can be an external atomizing nozzle. In one embodiment the airprovided for shearing can be heated to enhance the free-flow of theseparated masses beyond the point of shear.

In an alternative embodiment, the means for shearing can be a chamber inwhich the environment can be maintained to induce shear upon thecollision of a high velocity stream of feedstock directed against thepreselected and maintained environment. Generally, the temperature andhumidity of the shearing environment is maintained at a level whichinduces shear in feedstock (having internal flow) directed against thisenvironment at high velocity.

As a result of the present invention dry emulsions based on materialcapable of breaking down at high temperatures can be prepared. Theprocess is highly controllable and is able to produce high volumes ofshearform matrix with tight control of temperatures and/or low high-heatresidence times which minimize degradation of the feedstock or feedstockadditives.

The present invention has been shown to provide a shearform productwhich has a more amorphous structure, e.g., more random, than a productprepared from a solution process. The resulting matrix is capable ofdispersing more oil in water than with spun product. This isdemonstrated by greater tyndall effect. Thus, a maltodextrin having agiven D.E. will disperse a greater amount of oil as a shearform productthan as a spun product. This is believed to be the result of producing agreater number of finer particles which carry oil than can be producedby spinning. Also a much more stable dispersion can be established. Inorder to separate oil from a dispersion created with a shearform matrixether or hexane is required whereas heat and centrifugation is generallysuitable for separating oil from a dispersion resulting from a spunmatrix.

Other and further improvements which the present invention provides overthe prior art will be identified as a result of the followingdescription which sets forth the preferred embodiment of the presentinvention. The description is not in any way intended to limit the scopeof the present invention, but rather only to provide a working exampleof the present preferred embodiments. The scope of the present inventionwill be pointed out in the appended claims.

BRIEF DESCRIPTION OF THE DRAWINGS

Preferred embodiments of the invention have been chosen for the purposesof illustration and description and are shown in the accompanyingdrawings, wherein:

FIG. 1 is a schematic of the overall process and apparatus with theshear region detailed in FIGS. 2 and 3;

FIG. 2 is a detailed schematic of the encircled shear region II of FIG.1; and

FIG. 2a is a schematic as shown in FIG. 2 with phantom lines depicting apreferred embodiment which provides introduction of an additive withoutprolonged heating; and

FIG. 3 is yet a further detail schematic of the preferred ejectionarrangement for the preferred embodiment of the present invention.

FIG. 4 is a schematic depicting a high velocity nozzle and anenvironment-maintenance chamber as means for shearing feedstock.

DETAILED DESCRIPTION OF THE INVENTION

A shearform matrix according to the present invention is a matrix formedby transformation of a feedstock having a carrier material which has astructure capable of being altered by heating. The feedstock material isheated sufficiently to permit transformation of the morphology of thecarrier when it is subjected to a disruptive shear force. The conditionat which the disruption occurs is referred to herein as internal flow.Internal flow contemplates the ability of the material to move andseparate at subparticle level sufficiently to cause discontinuity in thefeedstock. In the context of the present invention the disruptive forceis applied to the stream of feedstock rather abruptly over a very shortperiod of time so that the duration of the force can be consideredinstantaneous.

The inventors have found that in a presently preferred embodiment of theinvention, the feedstock can be subjected to a stream of fluid, gas orliquid, impacting the feedstock at a velocity which creates the flashdisruptive shear force. The force created by fluid impinging against thefeedstock is referred to as disruptive fluid shear force.

Presently, the preferred fluid is air. However, the invention is notlimited to the type of fluid used to create the disruptive fluid shearforce.

In one embodiment air is directed against the feedstock as a continuoushigh velocity jet. Another embodiment contemplates propelling thefeedstock at high velocity against the force of an air atmosphere. Inboth cases the feedstock is abruptly disrupted into discretediscontinuous masses due to shear acting on the feedstock material whileit has internal flow.

Another characteristic of the shearform matrix of the present inventionis a morphology which results from allowing flash-disrupted feedstock toreform during free flow transformation from its original morphology.This unique free-flow transformation is achieved by preventing hindranceof continued flow while the material cools to a new matrix structure.

In order to provide the new matrix material of the present invention, aunique apparatus has been devised which is able to deliver the feedstockto a point where it is subjected to shear while in the internal flowcondition. The unique apparatus has several features which make ituniquely adept for this process.

Referring to FIG. 1, a twin screw extruder 10 provides the chamber inwhich the feedstock material is heated. Heating is controlled in theseries of heating zones 1-9.

The feedstock 18 is fed into the chamber from hopper/feed 12 innon-solubilized condition. By non-solubilized in the present inventionis meant that the ingredients have not been subjected to dissolution forpurposes of processing. A small amount of water (or other agents) may beused as a processing aid to ensure smooth flow, and assist generally inthe advancement of the throughput. These processing aids are notprovided, however, to change the nature of the feedstock fromnon-solubilized to solubilized.

The multiple-zone twin screw extruder has been used to effect controlledheating and feeding. The multiple zones are used to heat the feedstocksufficiently to attain a temperature at which internal flow occurs.Inasmuch as the temperature is increased inherently as a result offriction occurring during mixing and displacement with most feedstockmaterials externally supplied temperature can be reduced to a certainextent to accommodate the autologous temperature produced duringextrusion. In the examples which follow, extrusion was performed using aAPV Baker MPF50 twin-screw co-rotating extruder with an L:D ratio of 25to 1. Nine zones were provided for applying controlled heating betweeninput and exit. Screw configurations can be adjusted to meet therequirements of the process.

An important factor in the present invention is to heat and extrudefeedstock to attain a condition at which internal flow is possiblewithout going substantially beyond such point or creating an extendedresidence time in the extruder. This balance is achieved by selectingproper machine size, adjusting volume of throughput, selecting theoptimum screw design and heating at the separate zones to ensure thatinternal flow condition is met but not exceeded. Consequently, as soonas the proper condition is achieved, the extrusion is terminated bypassing the feedstock through an ejection means such as a nozzle.

In the first set of experiments which are described hereinafter, sugarwas processed as the carrier material and the balance of temperature andtime as explained in the preceding paragraph was satisfied by providinga nine-zone temperature profile and advancement speed set forth in TableI. Consequently, the sugar feedstock did not reside in the final threezones, i.e., Zones 7, 8 and 9, for more than about 90 seconds.

In the second set of experiments, maltodextrin was used as the carriermaterial in the feedstock and was processed using a temperature profileand advancement speed set forth in Table II to achieve the temperatureand time requirements. As a result the maltodextrin feedstock did notreside in the final three zones, Zones 7, 8 and 9, for more than about90 seconds.

In both cases, the feedstock was heated and advanced at a rate whichprovided internal flow conditions without substantially heating beyondsuch point and with minimum residence time under such conditions.Over-extension of either temperature or time results in deterioration ofthe carrier as well as creating of a non-processable mass of feedstock.

Additional ingredients 20, such as oleaginous material can be stored inreservoir 22 and metered into the feedstock by a pump 26. The mixing,pressurizing and advancing elements are shown schematically as screw 11.A head clamp or adaptor plate 15 has also been provided to direct thethroughput of feedstock from the extruder to the shearing portion of theapparatus designated by circle II. A detailed depiction of this regionis provided in FIG. 2.

Referring to FIG. 2, the ejection portion of the apparatus and processis schematically depicted. Specifically, feedstock 18 is derived fromextruder 10 under pressure and permitted to advance by use of a valvemechanism 32. Preferably a 3 port valve is used to direct the extrudedmass to an alternate outlet such as port 31 if required. Immediatelydownstream of the valve mechanism is a high pressure nozzle 34.

In the present preferred embodiment, the nozzle is a high pressure, lowvelocity nozzle which extrudes a substantially coherent stream offeedstock. In an alternative embodiment, the nozzle can be a highvelocity nozzle which extrudes the feedstock under high pressure and athigh velocity.

Referring again to FIG. 2, in the present preferred embodiment shear isprovided to the feedstock material while in the internal flow conditionby directing a stream of high velocity air against the coherent streamexiting the nozzle. The high velocity air can be provided by air stream42 which can pass through a filter and pressure/flow regulator 41 to amin-line heater 44 and a thermo-couple 43 to control the temperature ofthe air. The in-line heater 44 can be used to raise the temperature ofthe air to enhance the free-flow feature of the sheared masses separatedfrom the feedstock stream. Preferably, the air is heated to atemperature of about 130° C. to about 210° C. for sucrose and from about85° C. to about 180° C. for maltodextrins.

FIG. 2a depicts another embodiment which provides the ability to injectan additive to the feedstock at a point where it will not degrade beforebeing ejected. It is known that some ingredients, especiallybio-affecting active ingredients, are heat sensitive and willdeteriorate in the presence of prolonged heat condition. The presentinvention solves this problem by including an additive dispensing vessel70 from which an additive can be drawn along feedline 72. The newingredient can then be added along any one of injection ports 74, 76,and 78. Static mixers between 31 and 34 will achieve greater mixingefficiency when the ingredient is added at port 74. It should beunderstood that the present invention is not limited to theconfiguration shown in FIG. 20. Injection ports can be provided at anypoint in the process and apparatus described herein. The skilled artisancan select the desired configuration depending on the lability of theadditive and the characteristics of the apparatus used.

The stream of air is directed against the feedstock exterior by thenozzle to provide discontinuities in the feedstock and basicallytransform the morphology of the original feedstock to a new morphologyachieved by free-flow solidification as discontinuous masses. Referringto FIG. 3, air stream 42 is seen as being in fluid communication withannular channel 54 which surrounds the internal nozzle device 56.Feedstock 18 is shown being fed to the nozzle and exiting as a coherentstream 55 where it is subjected to high-velocity air stream 58 which iscreated by the combination of tortuous path exits provided by air cap 60and retaining ring 62.

Other measures can be taken to ensure that the internal flow conditioncreated in the extruder/heater is not lost by heat transier as theprocessed feedstock is advanced to the point of shear and beyond topermit free-flow reformation. For example, valve mechanism 32 can beheated to eliminate transfer of heat from the feedstock to a relativelycooler valve mechanism. Moreover, heat can be maintained at the point ofshear, generally identified by elements 60 and 62, by directing aheatgun at them during operation or by using a temperature controlledheating band. Alternatively, the temperature of the internal nozzle 56can be raised or lowered relative to a stream of heated air to preventtransfer of heat from the feedstock and consequent cooling below flowconditions. As the process continues, however, a steady-statetemperature of each of the mechanisms will be attained so thatadditional heat to individual elements of the operations is not requiredto prevent undue heat transfer and cooling.

When air is used to create the shear force, it is applied in a two-fluidnozzle at a pressure of from about 1.5 to about 20 atmospheres.Preferably, the pressure is applied at about 2 atmospheres to 10atmospheres. As previously mentioned, the temperature of the air used tocreate the shear force should preferably be controlled to a temperatureat least about 0.1° C. above the temperature of the feedstock beingejected for every atmosphere of pressure.

In each of the Examples which follow shear force was applied through atwo-fluid nozzle, shown in FIG. 3, by air fed at a pressure of about 3atmospheres. The temperature of the air was maintained before exitingthe nozzle at about 185° C. for sucrose and at about 150° C. formaltodextrin. When the pressure of the air at the nozzle shown at FIG. 3is 2 atmospheres, the velocity of the air impinging on the stream offeedstock is 68 feet per second, and when the pressure is 4 atmospheres,the velocity of air is 95 feet per second.

The unique process and apparatus disclosed herein will be furtherexplained and exemplified in actual experiments, the results of whichare set forth hereinbelow. These examples, however, are not meant tolimit the scope of the present invention.

EXAMPLES

Experiments have been run which test the premises of the presentinvention in actual use. The object was to determine whether or not atransformed shearform matrix could be produced from a non-solubilizedfeedstock. In order to do so, tests were conducted basically in twophases. The first phase employed a crystalline sugar (sucrose), as thesolid feedstock material or carrier. This sugar was fed to the twinscrew extruder as described above without solubilized feedstockcomponents. Furthermore, the sugar was processed with an oleaginousmaterial to determine whether or not an oleaginous component could besuccessfully incorporated as part of the shearform matrix product. Theresults were surprisingly quite favorable and demonstrate that acontinuous process can be employed for production on a commercial scale.

Sugar Examples

In the first experiments, sugar was processed in the extruder at a screwspeed of three hundred (300) revolutions per minute. The temperatureprofile of the extruder as well as the feed rate of the feedstock andprocessing aid has been set forth in Table 1. It is noted that water wasincluded as a processing aid in the experiments.

                                      TABLE I                                     __________________________________________________________________________    Sugar       Oil   Processing Aid                                                                        Temperature Profile °C.                      Experiment                                                                          Feed Rate                                                                           Feed Rate                                                                           H.sub.2 O                                                                             Zones                                               No.   (Kg/h)                                                                              (Kg/h)                                                                              (Kg/h)  1 2 3 4  5  6  7  8  9                              __________________________________________________________________________    1     36.0  --    1.0     30                                                                              50                                                                              90                                                                              180                                                                              180                                                                              200                                                                              200                                                                              200                                                                              200                            2     36.0  --    1.0     30                                                                              50                                                                              90                                                                              180                                                                              180                                                                              200                                                                              200                                                                              200                                                                              200                            3     36.0   3.6  1.0     30                                                                              50                                                                              90                                                                              180                                                                              180                                                                              200                                                                              200                                                                              200                                                                              200                            4     36.0  19.6  1.0     30                                                                              50                                                                              90                                                                              180                                                                              180                                                                              200                                                                              200                                                                              200                                                                              200                            5     36.0  11.8  1.0     30                                                                              50                                                                              90                                                                              180                                                                              180                                                                              200                                                                              200                                                                              200                                                                              200                            __________________________________________________________________________

In each of the experiments, sucrose in the form of crystalline sugar wasused as the dry feed. The temperatures shown in Table I start from thefirst zone (the zone closest to the inlet hopper of the extruder)through the ninth zone (the last zone adjacent to the exit). The feedwas ejected from the nozzle under a pressure of about 500 psig, e.g.,about 34 atmospheres.

Experiment No. 1

In the first experiment the product which was obtained using sucrosealone with a trace amount of water as a processing aid had an excellentappearance. The shearform matrix was substantially white in color andhad a white cotton wool texture. This material was easily adaptable formany uses in which the new shearform product would be consideredapplicable.

Experiment No. 2

In the second run the conditions were similar to those of the firstexperiment.. The product again appeared as a floss but had a slightlydarker color than the relatively unadulterated white appearing productof run number 1.

Experiment No. 3

In Experiment No. 3, the conditions were the same as Experiments No. 1and 2, except that oil was added to the feed to determine whether or notthe shearform matrix would be able to accommodate an additionalingredient such as an oleaginous material. In particular canola oil wasintroduced at a rate of 3.6 kilograms per hour. Otherwise the conditionswere kept the same as in the previous two experiments. The productobtained was a white, opaque cotton-like shearform matrix which wasacceptable in appearance and texture.

Experiment No. 4

In the next experiment, Experiment No. 4, the inventors increased theamount of oil to be incorporated in the shearform matrix by about 200%,e.g., from 3.6 Kg/h to 9.6 Kg/h. The remaining conditions were kept thesame as in the previous run.

The experiment produced an excellent product, which was clean white incolor and cotton-wool-like in texture. This is an excellent productconsidering that the oil content is approximately 21%. Furthermore, nooil separation whatsoever was detected.

Experiment No. 5

Finally, with respect to the sugar experiments, the oil feed wasincreased even further to a rate of 11.8 Kg/h for a content of about 24%in the final product. The feedstock processed very nicely under theconditions of the previous experiments and sprayed well from the nozzleinto a fluffy material which dispersed readily into the surroundingenvironment. The product was a beautiful white cotton-wool-like flossmaterial.

While other experiments were conducted to test variables in theprocessing of the matrix of the feedstock to produce the shearformmatrix, it was found that the process and apparatus devised forproducing the new shearform product were dependable on a commercialscale. In each of the experiments set forth above the shearform matrixproduct possessed a morphology which was quite different from themorphology of the sugar carrier in the feedstock.

The sucrose/oil product produced in the above experiments was added towater and produced very fine colloidal dispersions of the oil.

Maltodextrin Examples

Further experiments were performed with other solid feedstock materialto evaluate the capabilities of the invention. In particularmaltodextrin solids were used to discover whether or not a new shearformmatrix could be produced therefrom. The maltodextrin used in thefollowing experiments was Hubinger Dri Sweet 36. The conditions forthese experiments are shown on Table II.

                                      TABLE II                                    __________________________________________________________________________          Corn Syrup                                                                    Solids                                                                              Oil   Processing Aid                                                                        Temperature Profile °C.                      Experiment                                                                          Feed Rate                                                                           Feed Rate                                                                           H.sub.2 O                                                                             Zones              Screw Speed                      No.   (Kg/h)                                                                              (Kg/h)                                                                              (Kg/h)  1 2 3 4 5 6 7 8 9  (rev/min)                        __________________________________________________________________________    6     25    --    1.5     20                                                                              40                                                                              40                                                                              40                                                                              40                                                                              40                                                                              40                                                                              65                                                                              65 375                              7     20    4.1   --      20                                                                              20                                                                              20                                                                              40                                                                              40                                                                              60                                                                              60                                                                              85                                                                              85 350                              8     20    4.1   --      20                                                                              20                                                                              20                                                                              40                                                                              40                                                                              60                                                                              60                                                                              85                                                                              85 300                              9     20    4.1   --      20                                                                              20                                                                              20                                                                              40                                                                              40                                                                              60                                                                              60                                                                              85                                                                              85 350                              10    15    4.1   --      20                                                                              20                                                                              20                                                                              40                                                                              40                                                                              60                                                                              60                                                                              85                                                                              85 350                              11    15    3.4   --      20                                                                              20                                                                              20                                                                              40                                                                              40                                                                              60                                                                              60                                                                              86                                                                              100                                                                              350                              12    15    3.6   --      20                                                                              20                                                                              20                                                                              40                                                                              40                                                                              60                                                                              60                                                                              85                                                                              100                                                                              400                              __________________________________________________________________________

Experiment No. 6

Experiment 6 was conducted to determine whether or not a new shearformmatrix could be obtained from a solid maltodextrin feedstock without anyother components. In order to perform the experiment, maltodextrin wasfed at a rate of 25 Kg/h with a processing aid of water fed at a rate of1.5 Kg/h. The temperature profile is shown on Table II. The feedstockwas maintained at a very uniform flow to obtain a thin cotton-likeproduct which was evenly sprayed though the nozzle. The product wassatisfactory for use as a shearform matrix.

Experiment No. 7

Experiment No. 6 was run to determine whether or not oleaginous materialcould be incorporated into the new shearform matrix. Thus, oil was fedin with the feedstock maltodextrin at a rate of about 17% by weight,e.g., 4.1 Kg/h of oil to 20 Kg/h of dry maltodextrin feedstock. Thefeedstock was advanced at a processing rate of 350 rpm and at atemperature profile as shown in Table II. The result was very white,thin, brittle product which had no visible oil separation. Thus,oleaginous material can be successfully incorporated in a shearformmatrix produced from a dry maltodextrin feedstock.

Experiment No. 8

A further experiment was run similar to the conditions of Experiment No.7, but with a reduced processing speed of 300 rpm. The product was againin the form of very thin white particle product which showed no signs ofoil separation.

Experiment No. 9

Further experiments were run to confirm the results of Experiments Nos.7 and 8. In Experiment No. 9, the maltodextrin was processed with oilthe same as set forth in Experiment No. 7 to produce an attractive whitethin product which confirms the capability of reproducing a shearformmatrix from solid maltodextrin feedstock with oleaginous incorporatedtherein.

Experiment No. 10

In Experiment No. 10 the solid maltodextrin feedstock was reduced to arate of 15 Kg/h while the oil content was kept at 4.1 Kg/h. The productprepared in accordance with this experiment would contain a nominalamount of 21.5% oleaginous. The experiment was run under the conditionsset forth in Table II and the product obtained was the most attractiveof all of the experiments. It had a very low density and a high-qualitywhite appearance. The shape of the product was somewhat fiber-like.

Experiment No. 11

In Experiment No. 11 the temperature in the last barrel zone wasincreased to 100° centigrade and a heating element was installed on theball valve and a heat gun was directed to the nozzle to ensure that atemperature was maintained so that the product would remain in free-flowcondition as it exited and subjected to shear. The results wereexcellent. In Experiment No. 11 a 19% oleaginous content product wasobtained in the form of small, very white spicules with absolutely nobulk phase separation whatsoever in the product.

Experiment No. 12

The results of Experiment No. 11 were confirmed in subsequent experimentat which the production rate was increased by advancing the feedstockunder a screw speed of 400 rpm. Once again, the results were excellentin that a very white, small, thin spicule product resulted. Moreover, itwas possible to continuously run at the high speed for at least onehour.

As a result of the experiments set forth above, it has been determinedthat a dry feedstock material can successfully be transformed into a newmatrix for applications in many fields of technology.

Another embodiment (shown in FIG. 4) utilizes a single fluid nozzlewhich ejects feedstock 18' at high pressure and velocity, ejectingfeedstock from the nozzle at a velocity sufficient to causeinstantaneous disruption of the ejected stream in the ambient atmospherechamber 63. In a present preferred embodiment it has been found that thevelocity necessary to form shearform product can be created by providinga pressure of about 2,000 psi. The pressure will of course vary asnozzle size varies. Central to the process is that stream of feedstockbe ejected with sufficient velocity to create the separation of thestream into masses 59 of shearform product.

Thus, while there have been described what are presently believed to bethe preferred embodiments of the present invention, those skilled in theart will realize that other and further modifications can be madewithout departing from the true spirit of the invention, and is intendedto include all such modifications and variations as come within thescope of the claims as set forth below.

We claim:
 1. A process for making a shearform matrix comprising:a)controlledly increasing the temperature of a feedstock which includes asolid non-solubilized carrier material capable of undergoing internalflow in the absence of dissolution to a point where said carriermaterial will undergo internal flow with the application of disruptivefluid shear force; b) ejecting said heated feedstock resulting from step(a) as a coherent stream under pressure from at least one orifice; andc) then subjecting said coherent stream of feedstock to a disruptivefluid shear force which separates said coherent stream of feedstock intomultiple discrete and discontinuous parts and transforms the morphologyof said feedstock into said shearform matrix.
 2. A process according toclaim 1 wherein said multiple parts are cooled to a temperature belowsaid internal flow point immediately after contact with said fluid shearforces and separation of said stream into multiple parts.
 3. The processof claim 1 wherein an environment is provided for said multiple parts toreform as solid shearform matrix under conditions which permit free-flowuntil solidification.
 4. The process of claim 1 wherein said carriermaterial selected from the group consisting of saccharide-basedmaterials, thermoplastic polymers, biodegradable polymers, andcellulosics.
 5. The process of claim 4 wherein said feedstock furthercomprises a crystallization control agent.
 6. The process of claim 5wherein said crystallization control agent is an antihumectant.
 7. Theprocess of claim 5 wherein said feedstock comprises an oleaginousmaterial selected from the group consisting of vegetable oils, soy beanoil, canola oil, corn oil, sunflower oil, animal fats, tallows, lards,fish oils, crustacean oils, and mixtures thereof.
 8. The process ofclaim 4 wherein said feedstock further comprises an additive selectedfrom the group consisting of bio-affecting agents, dyes, fragrances,crystallization control agents, sweeteners, flavors, and mixturesthereof.
 9. The process of claim 1 wherein said temperature iscontrolledly increased to said internal flow point in the substantialabsence of heating beyond said point and with minimum residence timeduring said controlled temperature increase.
 10. The process of claim 9wherein said feedstock is simultaneously pressurized.
 11. The process ofclaim 9 wherein said controlled temperature increase is provided bypassing said feedstock through a feeder chamber having multipletemperature-control zones.
 12. The process of claim 11 wherein saidfeedstock is passed through said multiple zones under conditions whichprevent heating substantially beyond said internal point and whichminimizes time in said chamber.
 13. The process of claim 4 wherein saidfluid shear force results from directing a fluid at high velocity atsaid stream of extrudate.
 14. The process of claim 13 wherein saidfeedstock is sucrose and said fluid is air maintained at a temperatureof from about 160° C. to about 200° C. and ambient atmosphere has arelative humidity of less than 30% RH.
 15. The process of claim 13wherein said feedstock is maltodextrin and said fluid is air maintainedat a temperature of from about 85° C. to about 180° C. and ambientatmosphere.
 16. The process of claim 4 wherein said fluid shear forceresults from extruding said feedstock through said nozzle at highvelocity against a fluid atmosphere at a condition which providesdiscrete, discontinuous masses.
 17. An apparatus for making a shearformmatrix comprising:means for advancing, and controlledly increasing thetemperature of a feedstock which includes a solid non-solubilizedcarrier material and applied pressure on said solid non-solubilizedcarrier material to the point where said carrier undergoes internal flowand is simultaneously advanced for ejection; means for ejecting saidfeedstock as a coherent stream for shearing said feedstock to providesaid shearform matrix, said means for ejecting in a fluid communicationwith said means for increasing the temperature and pressure and arrangedto receive said feedstock material during said internal flow condition;and means for disruptively shearing said feedstock fixed proximally tosaid means for ejection and disposed for effecting shear of saidcoherent stream of feedstock during said internal flow condition intomultiple discrete and discontinuous masses whereby said feedstockmaterial is transformed to said shearform matrix.
 18. The apparatus ofclaim 17 wherein said means for increasing the temperature comprises amultiple-zone chamber having selectively heatable zones and a continuousthroughput mechanism for advancing said feedstock.
 19. The apparatus ofclaim 18 wherein said throughput mechanism comprises at least one screwmechanism for extruding said feedstock.
 20. The apparatus of claim 19wherein said means is a twin screw extruder having at least four heatingzones.
 21. The apparatus of claim 20 wherein there are nine heatingzones.
 22. The apparatus of claim 17 wherein said means for ejecting isa high pressure nozzle.
 23. The apparatus of claim 22 wherein saidnozzle is a low velocity nozzle which provides a substantially coherentstream of said feedstock at an exit orifice.
 24. The apparatus of claim22 wherein said nozzle is a high velocity nozzle having at least oneopening for ejecting feedstock at high velocity.
 25. The apparatus ofclaim 17 wherein said means for shearing said feedstock comprises meansfor delivering fluid for high velocity against feedstock as it exitssaid means for ejecting.
 26. The apparatus of claim 25 wherein saidmeans for delivering fluid comprises an external atomizing nozzle. 27.The apparatus of claim 24 wherein said means for shearing comprises anenvironment-maintenance chamber which maintains an environment whichinduces shear upon collision of said high velocity feedstock againstsaid environment.
 28. The apparatus of claim 17 wherein said apparatuscomprises means for injecting an additive to said feedstock at a pointproximal said means for ejecting said feedstock.